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Custom Engineering

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We emphasize close customer support and availability for unique design engineering. The following scenario describes the step-by-step process of a custom-engineered orbital welding system.

 
 

Case Study: Custom-Engineering for heavy-wall, “hairpin” return bend

 
Step By step Process:  

Customer contacts AP Automation with job requirements:

 
  • Orbital welding on 3” schedule XX (.600" wall)
  • Hairpin return bend heat exchanger
  • 2 ½" radial clearance, 1 ¼" axial clearance and tight clearance between return bends.
  • 100% X-Ray Orbital TIG required.

AP Automation Custom-Engineers a Welding System:
AP Automation determines that the smaller AP 36-80 weld head must be used instead of the AP 70-160 because of clearance restrictions. The AP 36-80, built for maximum 3 1/8" OD, is custom-modified to weld the 3 1/2" OD pipe. This enables a tight 1 3/4" radial clearance for the job.

 
 
Solidworks® 3D CAD model is created and emailed:  
This allows the customer to view on his web browser an animated simulation of his job being welded with one of our weld heads. The customer can zoom in and manipulate the image to view all of his clearance requirements and verify our equipment for his job. No extra software is required to view the model. A PowerPoint® presentation  
detailing the system is also emailed.  
 
Customer Review:
After necessary modifications and approval, AP Automation sends a quote for the system and optional lab work to the customer.
 

 

 
Job Simulation, Time Study and Weld Tests:
If necessary, a mock-up of the job is welded in our lab. After we perform a series of welds similar to the actual production environment, we produce a time study so the customer knows how many welds one operator can perform in an 8-hour day. 50% of the charge for this service is credited back with purchase of the equipment.
 
 
After the lab work is completed, the customer receives a full report with weld samples, joint design options, time study, weld parameters and video of the parts being welded. Customer then completes a full inspection of the parts. Upon approval, a purchase order with deposit is issued.  
 
Joint Design Options
Weld Samples
   
       

AP Automation builds, tests, and installs the customer’s system:
After building the system, we perform extensive weld testing, then ship the system to the job site. Once equipment arrives, a technician from AP Automation works with the customer in three steps:

  1. Equipment setup and installation
  2. Operator Training: equipment use & maintainance.
  3. Working with customer’s technicians, we assist in developing weld parameters for the job.
 
 
 
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AP Automation maintains customer service and technical support for immediate assistance.
 

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